The Bike Lite Glow Using CCFL

Step 6 The power box

Ok so now we'll setup the lights and their power source. Remember that warning about HIGH VOLTAGE in the beginning? Yeah, PAY ATTENTION !! This is where we deal with that subject. My tubes are approx. 620 volts !! DO NOT power up the circuit without it's case. If you do, you can get zapped. You have been warned....

First I removed the circuit from the case. My case just unsnaps. Your case may have screws, be glued, etc. This is my circuit. Of note, there are no large capacitors in this circuit so it is unlikely that you can be shocked as long as power is not applied. I was wondering what I was going to do with the switch when I noticed that there is enough room in the case to mount the switch!! How cool is that!!

First I set about dismantling the switch harness.

Unsolder the wires from the switch.

Next remove the switch from the bracket. Cut the wire ties and the black wire from the computer connector.

Using the bracket, trace onto the case the location of the switch.

Drill the holes for the screws, then use a drill slightly larger than the switch. Make two holes in the large part of the switch template and clean up with an x-acto knife.

Mount the switch in the box.

Take the circuit board flip it over.

Next to the power connector you'll see a trace. Your board may be different but the principals are the same.

Cut the trace indicated by the photo.

Note the two arrows. Using the leftover yellow wire, prepare two pieces that will go from those solder pads to the switch.

Notch the circuit board as indicated by the photos, then solder the wires to the pad and then to the switch. (see Photo for detail)

Next prepare the power wire with heat shrink and sleeve just as you did for the tubes.

Now solder on the N size plug to the power cable.

Now snap on the cover on the box. plug the lights into the box. Connect the battery pack and switch it on.

Works? Congratulations !! You are almost done!!

Does not work? Check your battery charge, switch connections (look for shorts opens etc.)

The last thing to do is glue the four corners of the box, then glue on the magnets as shown.

Congratulations !! Your done !! Now mount it to your bike and go show it off ! I have a pouch under my seat that I carry my tools, amp( that is another instructable...) and that is where I put my battery pack. Route the wires to where you need to mount your lites. Make sure that the wires do not interfere with the safe operation of your bike. Have fun!!

!!! MINOR UPDATE !!!
The following is also posted in comments:

Hey just to let everyone know, I had trouble recently with one tube going dim while the other was bright. After some troubleshooting, I discovered that the connectors (Sockets for the light tubes) in the powersupply box had cracked solder connections. Re soldering these connections has fixed the trouble for now but I think I need to find a better connector that can take the connect/disconnect cycles that this project goes thru. If you left the lights on your bike all the time, it is likely you will not experience the dim tube syndrome. Anyway I hope this helps. Take care, thanks for looking !!

Comments

[Koil_1]

If you don't have a Dremel I would highly recommend getting one. For this kind of project they are invaluable. Not only is it easier to shape and drill plastic, it's also very easy to notch PC board. They are wonderful tools to have and the lower models can be purchased for under $30.00. I have personally burned through 7 Dremels through my hobby rich life. I use them until the barrings die. I don't have a hydrolic press so it's kind of hard for me to change those. Something that lasts 4 years and is usefull for just about everything is well worth it. Trust me, you get one of them and you'll be impressed enough that you'll look for other things to use it for just to use it. They're addictive...

[digitaltripper]

Yeah great idea !! on the first box I used a Dremmel w/ drum sander. Worked perfectly. Second one used the xacto.